Manufacturing Readiness Levels (MRLs) and Manufacturing Readiness Assessments (MRAs)

Transcription

1 Manufacturing Readiness Levels (MRLs) and Manufacturing Readiness Assessments (MRAs) Jim Morgan Manufacturing Technology Division Phone # Jim.Morgan@wpafb.af.mil

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3 Outline Why Manufacturing Readiness? Manufacturing Readiness Levels & Assessments Implementation of MRLs MRA Tools Example results Policy Status Closing Thoughts 2

4 Why Manufacturing Readiness? Manufacturing & Industrial Base Challenge Consensus among Congress, OSD, CSAF, GAO: Advanced weapon systems cost too much, take too long to field, and are too expensive to sustain GAO study of 54 weapons programs: Core set of 26 programs: RDT&E costs up by 42% ($42.7B total) and schedule slipped by 20% (2.5 years on average) Characteristics of successful programs (GAO): Mature technologies, stable designs, production processes in control S&T organization responsible for maturing technologies, rather than program or product development manager Products made by immature manufacturing processes generally: - Cost more - Are prone to quality problems - Experience schedule delays - May not perform the same - Are less reliable in service 3

5 Today s Air Force Reality Diminishing manufacturing infrastructure People, policy, programs gutted Lost recipe on how to manage manufacturing risk Won t get infrastructure back, but still need to manage and mitigate manufacturing risk Utilize MRL/MRA as a tool Supports knowledge-based acquisition Integral to Systems Engineering Plan Essential for effective and efficient transition of capability to the warfighter 4

6 Technology Readiness Levels (TRLs) and Manufacturing Readiness Levels (MRLs) TRLs provide a common language & widely-understood standard for: Assessing the performance maturity of a technology and plans for its future maturation Understanding the level of performance risk in trying to transition the technology into a weapon system application TRLs leave major transition questions unanswered: Is the technology producible? What will these cost in production? Can these be made in a production environment? Are key materials and components available? MRLs assist in answering these questions MRLs provide a common language and standard for Assessing the manufacturing maturity of a technology or product and plans for its future maturation Understanding the level of manufacturing risk in trying to produce a weapon system or transition the technology into a weapon system application 5

7 MRL Relationships Relationship to System Acquisition Milestones Pre-Concept Refinement Concept Refinement Technology Development System Development & Demonstration Production & Deployment A B C MRL 1 MRL 2 MRL 3 MRL 4 MRL 5 MRL 6 MRL 7 MRL 8 MRL 9 MRL 10 Mfg Feasibility Assessed Mfg Concepts Defined Mfg Concepts Developed Manufacturing Processes In lab Environment Components In Production Relevant Environment System or Subsystem In Production Relevant Environment System or Subsystem In Production Representative Environment Pilot Line Demonstrated Ready for LRIP LRIP Demonstrated Ready for FRP FRP Demonstrated Lean Production Practices in place TRL 1 Basic Principles Observed TRL 2 Concept Formulation TRL 3 Proof of Concept TRL 4 Breadboard in Lab TRL 5 Breadboard in Rep Environment TRL 6 Prototype in Rep Environment TRL 7 Prototype in Ops Environment TRL 8 System Qual TRL 9 Mission Proven Relationship to Technology Readiness Levels 6

8 1. Technology and Industrial Base Nine MRL Evaluation Criteria ( Threads ) Technology maturity, technology transition to production, ManTech development 2. Design Producibility program, design maturity 3. Cost and Funding Production cost knowledge (cost modeling), cost analysis, mfg investment budget 4. Materials (raw matls, components, subassys, subsystems) Maturity, availability, supply chain management, special handling 5. Process Capability and Control Modeling & Simulation (product & process), mfg process maturity, process yields/rates 6. Quality Management, to include supplier quality 7. Manufacturing Personnel, to include specialization, training, & certification 8. Facilities, to include capacity and plant layout & design 9. Manufacturing Management Manufacturing planning and scheduling Materials planning Tooling and special test equipment

9 What is a Manufacturing Readiness Assessment? An Assessment of a Program s Readiness to Manufacture and Produce its Intended Design A Tool to Develop and Implement - Manufacturing Risk Mitigation Plans Business Strategies Effects of Design Changes (Planned Upgrades, Spiral) Pricing Agreements (Long Term vs. Single Lot) Capital Investment Plans (Contractor and/or Government) Results in an Assignment of MRLs to Key System Components and Development of a Manufacturing Maturation Plan as Required 8

10 MRA Deliverables Provide briefing and/or written report Identify current MRL/target MRL Identify key factors where manufacturing readiness falls short of target MRL Define driving issues Identify programs and plans to reach target MRL Assess type and significance of risk to cost, schedule or performance Next step: Stay engaged to assist in implementing and executing the Manufacturing Maturity Plan 9

11 Implementing MRLs: Who is Using Them? Mandated by AFRL for all Category 1 hardware ATDs and certain high-visibility programs Selected Air Force acquisition programs, including all at AAC Army using on Future Combat Systems development efforts Missile Defense Agency Industry has adopted and is using MRLs within their gated processes And the list is growing

12 MRL Implementation Approach Conduct pilot MRAs on various programs Hardware-intensive Category 1 ATDs Weapon system acquisition programs Conduct tailored training for key program personnel Category 1 ATD IPTs, ACAT pilot program, and Air Force Product Centers Transition training DAU for awareness and policy AFIT for in-depth MRA and manufacturing instruction Put MRLs into policy documents AFRL, AFMC, AF, OSD Socialize MRLs whenever possible Develop and deploy Manufacturing Readiness products Continuously refine products based on feedback, need

13 MRL/MRA Products/Tools Most of our MRL products/tools have been developed with other Services and industry MRL definitions, entry/exit criteria MRL training blocks (2-hr, 4-hr, multi-day) MRA Deskbook (modeled after TRA Deskbook) Pre-MRA self-assessment questionnaire Excel-based MRA tool Draft DoD and AF policy Defense Acquisition Guidebook language MRA frequently asked questions repository

14 MRA Results Examples Focused Lethality Munition - ready for LRIP Eglin High Explosive Research Development facility originally assessed at MRL 5 (May 07); now at MRL 8 Aerojet composite warhead case originally assessed at MRL 5 (March 07); now at MRL 8 AMRAAM C-7 - production rate increased from <10 to 28+ per month F135 Propulsion Persistent Strike - accelerated F135 thrust improvement by ~4 yrs w/plan to mature advanced casting producibility from MRL 3 to 5 MQ-9 Reaper

15 MRL Policy Status Goal: Establish manufacturing risk management as a tenet of acquisition management Recommended levels MS A MRL 4 MS B MRL 6 MS C MRL 8 FRP MRL 9 Not designed to be a go/no-go criteria OSD (AT&L) recently sent a draft policy memo to the Services Services and OSD Systems Engineering nonconcurred; suggested MRL use at MS C only Expect AT&L to press forward with revised language in coming weeks

16 Some MRA Lessons Learned Process is more effective if company and program office are actively engaged in the assessment System integration and test operations are often ripe for maturation efforts With few exceptions, requires feet on the (shop) floor Resources required to conduct an MRA will vary significantly Not all programs are equal Subject matter expertise is needed to do it right Templates and guidelines developed Not a one size fits all solution Engineering skills/judgment still needed Must avoid a checklist mentality

17 Closing Thoughts Feedback from those who have applied MRLs thus far has been positive Expectations management is important; MRLs will not solve world hunger Congress, National Defense Industry Association and other industry consortia have been vocally supportive Policy implementation pending, but many are using as a best practice and DAU is including MRLs in courses Fits well within Defense Systems Engineering construct, but should not be diluted to the point of becoming ineffective (e.g. PRRs) 16